Self-compensating magnetoelastic torque sensor system

ABSTRACT

An improved magnetic torque transducer arrangement for self-compensating effects of external magnetic sources and temperature offset comprises a shaft with at least one magnetized zone, at least one active magnetic field sensor and at least one passive magnetic field sensor disposed in such a way that active field sensor always in a position with higher magnetic field strength arise from applied torque than that of passive sensor. Passive field sensors may also be placed in both sides of the active field sensor, or on one side of active field sensor only. The transducer output is obtained by subtract the output of passive field sensors from that of active field sensor thus cancel out the effect of interfering magnetic field flux and temperature offset on the torque transducer, and partially filter out temperature sensitivity drift and rotational dependant signal. The sensitivity of active and passive field sensors can also be electrically matched by calibrating them in a uniform magnetic field, thus a completely common mode rejection can be achieved. The sensor arrangements may also be utilized in other type of sensors that extract changes in magnetic fields to indirectly detect direction, speed, presence, force, linear position, or angle to cancel out interfering magnetic field and temperature offset effect.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

FEDERALLY SPONSORED RESEARCH

Not Applicable

SEQUENCE LISTING OR PROGRAM

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the field of using magnetic sensors to measure torque applied to a rotatable shaft. More particularly, the invention relates to the particular placement of magnetic field sensors in relation to a magnetic transducer element to measure the torque applied to a shaft, and the sensor system is immune to external magnetic sources within a large temperature range.

2. Prior Art

Magnetic torque sensors are known in the art. Many versions of this type of magnetoelastic torque sensor have been proposed and described in a plurality of publications and patent specifications. There are two general ways of utilizing the magnetoelastic phenomenon as the sensing mechanism for non-contacting torque sensor. One is permeability based, and the other is Polarized Band based.

In Permeability Based type of magnetoelastic torque sensors, the permeability changes in the shaft surface, caused by the stress-induced magnetic anisotropy, affect the permeance of a magnetic flux path which includes a magnetizing source and a sensing coil. In these type of devices the magnetic property effectively sensed is a permeability μ, of one form or another, the output signals are derived from a magnetic flux density B of a flux arises in response to an excitation field H with B=μH, where μ is altered by the stress and hence by the transmitted torque, this results in different voltages being induced in the sense winding encircling the two regions and this difference provides the measure of the torque. This kind of transducer comprises a shaft with surrounding excitation windings and measuring windings. Concentrically with the windings, anisotropic measuring zones are created in the shaft by different methods, e.g. by attaching a sleeve of magnetic material, formed with two parallel, annular zones which are provided with slits having a substantially regular pitch and making an angle of ±45° with a generatrix of the envelope surface of the sleeve (U.S. Pat. No. 4,506,554, Blomkvist et al.). Or by applying layers, such as copper strips, on the surface of the shaft. (U.S. Pat. No. 5,646,356, Ling et al.) Another method is form a series of parallel grooves and/or lands or protuberances inclining at a suitable angle with the longitudinal axis of the shaft. (U.S. Pat. No. 4,823,620, Edo et al.). Or a shaft having a magnetostrictive film (Pub. No. U.S. 2007/0245833 A1, Yoneda et al.), or a pair of amorphous magnetic ribbons bonded to a shaft. (U.S. Pat. No. 4,907,462, Obama et al.)

An example of a commercially offered permeability based magnetoelastic torque transducer is that offered under the Trade Mark Torductor by the Force Measurement division of ABB AB, S-721 59 Vasteras, Sweden.

In Polarized Band type of magnetoelastic torque sensors, sensor operation is based on the reorienting effects of torsional stress on the individual magnetic moments that have been remanently circularly magnetized. In response to the magnetoelastic energy associated with the biaxial principal stresses by which torque is transmitted along the shaft, each moment will rotate towards the nearest positive principal stress direction and away from the nearest negative principal direction. This reorientation of the originally circular magnetization results in a net axial magnetization component. The divergence of this component at the edges of the polarized bands is the source of a magnetic field in the space around the shaft that can be readily measured with one or more magnetic field sensors. This type of transducers can be constructed either with a thin ring of magnetoelastically active material rigidly attached to the shaft (U.S. Pat. No. 5,351,555, Garshelis), or by using a portion of the solid or hollow shaft itself as the magnetoelastically active element (U.S. Pat. No. 6,047,605, Garshelis, and U.S. Pat. No. 6,581,480 B1, May et al). The magnetoelastic zone may also be remanently longitudinally magnetized.

An example of a commercially offered Polarized Band based magnetoelastic torque transducer is that offered by the Magna-Lastic Devices, Inc, a division of Methode Electronics, Inc, 7401 W. West Wilson, Chicago, Ill.

The basic weakness in these prior art approaches to magnetoelastic torque transducers is that they can't distinguish whether the sensed quantity, i.e., magnetic flux B, is depended on torsional stress induced by applied torque or an external magnetic flux source, or a temperature dependent magnetic flux, thus with the undesirable result that the sensed variations in B do not unambiguously indicate a variation in torque.

Most prior art devices employ a construction of common mode rejection to filter out uniform external magnetic flux, known as far field, e.g. earth magnetic field, by providing two distinct B dependent signals, having equal quiescent value but opposite responses to torque, with means for combining the two signals differentially. This demands great care in matching the sensitivity of the two magnetic flux B sensors. And this configuration can't eliminate non-uniform external magnetic flux sources, known as near field, such as a nearby electric motor, or a nearby moving ferromagnetic object.

Another attempt to avoid external magnetic flux is to positioning a magnetic shield around transducer to protect it from external magnetic source, as detailed in U.S. Pat. No. 5,083,359(Aminder et al) and U.S. Pat. No. 5,889,215(Kilmartin et al).

There is yet another attempt to compensate the interference field by energizing coils to provide a counteracting magnetic field as detailed in U.S. Pat. No. 6,826,969 B1 (May).

Unfortunately, providing sufficient space for the requisite shield and counteracting coils has created practical problems in applications where space is at a premium, also, such shield appear to be impractically expensive for using on highly cost-competitive devices, such as in automotive applications, and these approaches increase the complexity and the cost of a complete sensor while also generally reducing its adaptability, maintainability and reliability. These approaches also do not compensate for temperature offset effect and rotation-dependent output.

SUMMARY OF THE INVENTION

The present invention was devised to provide a magnetoelastic torque transducer that can overcome aforementioned problems, and one object of the invention is providing a torque transducer having high reliability.

Another object of the invention is to provide a magnetoelastic torque transducer in which inherently filter out the effects of external magnetic flux sources.

A further object of the invention is to provide a magnetoelastic torque transducer that can inherently compensate for temperature offset.

Another object of the invention is to provide a magnetoelastic torque transducer that compensate for rotation dependent output.

A further object of the invention is to provide a magnetoelastic torque transducer that can compensate for temperature sensitivity drift.

Another object of the invention is to provide a magnetoelastic torque transducer that requires less axial space, and with greater tolerance on shaft axial movement.

An additional object of the invention is to provide a magnetoelastic torque transducer which symmetry match the sensitivity of paired magnetic flux B sensors electrically so that a complete common mode rejection can be accomplished.

These objects and others are achieved by providing a torque sensor comprising at least one magnetoelastically active element, at least one magnetic field sensor, responsive to the field of the magnetoelastically active portion arise from applied torque (active field sensor), and at least one magnetic field sensor that does not responsive the field of the magnetoelastically active portion arise from applied torque, so that this sensor can't sense most of or all of the magnetic flux caused by applied torque(passive field sensor). The output signals of active and passive field sensors are independently processed, when there is magnetic flux variation detect by the active field sensor(s) approximate to active transducer zone and little or no magnetic field variation is sensed by the passive field sensor(s), that means all the magnetic field variation sensed by the active field sensor(s) is cause by applied torque. When there are magnetic field flux variation detected by both active and passive field sensors, it indicates that there are external magnetic flux, be it caused by temperature changes, rotating shaft, or an external magnetic source e.g. an electrical motor.

Alternatively, passive field sensor or sensors can be placed approximate to the active magnetoelastic zone with lower field strength than that of active field sensor to partially compensate rotational dependent signal and temperature sensitivity drift.

To establish precise symmetry in the two magnetic flux B sensors demands great care, and in real world it's very hard to achieve, thus common mode rejection is not completely effective without precise symmetry matched field sensors. When place the torque transducer in a uniform magnetic field, since the output of active and passive field sensors is separated, their sensitivity can be electrically adjusted to achieve precise symmetry.

The invention permits lower manufacturing cost and ease of use as compared with the prior transducer technology, and the sensor system is robust enough for most harsh environments.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 shows a 3-dimensional representation of the present invention.

FIG. 2 shows a 2-dimensional representation of the present invention.

FIG. 3 shows axial magnetic field strength across active magnetoelastic zone.

FIG. 4 shows field sensors placement in a transducer does not perfectly line up in real world due to manufacturing tolerance.

FIG. 5 a through 5 c show alternative embodiments of the torque transducer.

DRAWINGS—REFERENCE NUMERALS

10 Axis 12 Shaft 14 Active Magnetoelastic zone 16 Magnetic Passive Area 18 Active Field Sensor 19, 20 Passive Field Sensor 22 Wire 24 Magnetic Flux Dependent On Torque 26 External Magnetic Flux

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 and FIG. 2 illustrates a preferred embodiment of a Polarized Band based torque sensing apparatus in accordance with the invention in 3D and 2D respectively. In this exemplary embodiment, the torque carrying shaft 12 having a torque T applied about a central longitudinal axis 10, the shaft 12 has an magnetoelastically active portion 14, at least one active field sensor 18 is placed approximate to this magnetoelastically active portion 14 to detect the magnetic flux 24 arise from applied torque, and at least one passive field sensor, 19 or 20, is placed on either side of the active field sensor 18, passive field sensors 19 and 20 are disposed in such a way that they are far away enough from magnetoelastically active portion 14 to avoid the magnetic flux 24 dependent on applied torque T.

FIG. 3 shows axial magnetic field strength arise from applied torque T across magnetoelastic active zone 14, the zone having a peak field strength in the center of the zone 14, and its strength gradually reduce toward the edges of the zone 14. The longer the zone 14, the flatter the peak. So a longer magnetoelastic active zone can be utilized to minimize the effect of axial movement of the shaft.

The outputs of the active field sensor 18 and passive field sensors 19 and 20 are brought out by wire 22, one way to filter out unwanted magnetic flux is use following formula to process output signals of these field sensors:

${Output} = {S_{a} - \frac{S_{p\; 19} + S_{p\; 20}}{2}}$

where

Output=Transducer's output

S_(a)=Output of active field sensor 18

S_(p19)=Output of passive field sensor 19

S_(p20)=Output of passive field sensor 20

If there is no torque applied and there is no external magnetic flux source present, S_(a) equals to S_(p19) and S_(p20) respectively, thus the output of transducer is 0.

If a torque T is applied to the shaft 12, only active field sensor 18 is reacted to the magnetic flux 24 generated by the applied torque T, S_(a) will increase or decrease depending on the direction of torque T, so the output of the active field sensor 18 is S_(a)+S_(t), where S_(t) is signal change dependent on applied torque, and when there is no change in external magnetic flux, S_(p1) and S_(p2) will remain the same as that before the torque T is applied, all the quantity sensed by active field sensor 18 is arise from applied torque T and the output formula is as following:

${Output} = {{\left( {S_{a} + S_{t}} \right) - \frac{S_{p\; 1} + S_{p\; 2}}{2}} = S_{t}}$

Magnetic flux variations 26 detected by passive sensors 19 or 20 indicate magnetic flux sources other than that cause by applied torque. There are several types of interfering magnetic flux sources. The strength of a magnetic field drops off roughly exponentially over distance, depending on the distance from interfering magnetic sources to the transducer, they can be classified into far fields and near fields. When an interfering magnetic source is far away enough, i.e. earth magnetic fields, the distance between the external magnetic source and the active and passive field sensors 18, 19 and 20 can be considered the same, hence, outputs of all field sensors caused by far fields is equal to each other. And the formula become:

${Output} = {\left( {S_{t} + S_{ea}} \right) - \frac{S_{{ep}\; 19} + S_{{ep}\; 20}}{2}}$

where

S_(ea)=Output of active field sensor 18 cause by external magnetic flux 26

S_(ep19)=Output of passive field sensor 19 cause by external magnetic flux 26

S_(ep20)=Output of passive field sensor 20 cause by external magnetic flux 26

Since S_(ea)=S_(ep19) and S_(ea)=S_(ep20) when the external magnetic flux is uniform over the length of the transducer, the output signal of active field sensor 18 and passive field sensors 19 and 20 cause by far field cancels each other out.

When an interfering magnetic source is closer to the transducer, the signal output of passive field sensor closer to the external source will be largest, and smallest in the passive field sensor farther away to the external source, output of active field sensor 18 will be between that of the two passive field sensors because its distance to the external source is between that of passive field sensors 19 and 20. For a given primary near field source, there is a setup that can place passive sensors 19 and 20 in relative to the active field sensor 18 so that the active field sensor's output is the average of passive field sensors, thus the effect of this particular near field can be cancel out completely. This set up, of course, can't be adapted to completely cancel out effects of different near fields at the same time, however, a certain variation cause by near fields is permitted in most cases.

For applications with very high demands for accuracy, another algorithm can be utilized to minimize the effect of near fields. If output signal varies in a small time interval of passive field sensors S_(p19) and S_(p20) are equal, it indicates that active field sensor 18 also experience the same non-torque output signal variation. If the changes of one passive field sensor's output is bigger than that of the other, it indicates that there is near field source or sources come in, according to relative location of passive field sensor 19 and 20 to each other and to the active field sensor 18, the output signal variation arise from near field effect on the active field sensor 18 can be determined from known output changes of both passive field sensors and then filtered out, thus only torque signal will be converted to finial transducer output.

There is slight sensitivity different between magnetic field sensors due to manufacturing tolerance, moreover, when assemble and solder field sensors into a complete transducer, field sensor's position won't be perfectly inline with each other, again due to manufacturing tolerance, as shown in FIG. 4, which results in output variation when they subject to the same magnetic flux. This shortcoming can be overcome by calibrating the sensitivity of each group of field sensors after assembly, by putting the completed transducer in an uniform magnetic field, such as inside a helmholtz coil, and compare the output of field sensors in each group, electrically match them if they are not identical. After doing so, each group of field sensors will have the same signal output when subject to the same magnetic field flux. This sensitivity matching can be done in x, y, and z direction. And common mode rejection is then completely achieved.

If there is uniform temperature variation across the length of the transducer, then all passive and active field sensors will experience the same output offset, if there is gradient variation of temperature along the length of the transducer, then the temperature offset of active field sensor 18 is close to the average temperature offset of passive field sensor 19 and 20, in both cases, temperature offset of the transducer will be automatically eliminated using the above signal process algorithms.

Alternatively, passive field sensors 19 and 20 can also be placed close to magnetoelastic active zone 14, where their location has lower field strength than that of active field sensor 18, as shown in FIG. 5 a, there are several advantages of this arrangement, it require less axial space, it also partially compensate for temperature sensitivity drift, and partially compensate for rotational dependent output, since any temperature sensitivity drift and rotational dependent signal detected by active field sensor 18 will also experienced by passive field sensors 19 and 20. Although this arrangement will lower the transducer's sensitivity, with the above self-compensating feature, however, the transducer still capable of providing highly accurate measurement, immune from interfering external magnetic sources.

FIG. 5 b and FIG. 5 c show another kind of field sensor arrangement with passive field sensor 19 placed on only one side of the active field sensor 18. This kind of arrangement can be use in applications where the transducer is protected from near fields.

Although these field sensor arrangements is shown and explained in Polarized Band based magnetoelastic torque transducer, they may also be utilized in permeability based type of magnetoelastic torque transducer, by placing pickup coils without excite coils (passive field sensor) on either side of excite/pickup coils (active field sensor). Further more, other magnetic field sensing devices, such as magnetic speed sensor, magnetic linear position sensor, magnetic angle sensor, magnetic force sensor can also utilized

If there is uniform temperature variation across the length of the transducer, then all passive and active field sensors will experience the same output offset, if there is gradient variation of temperature along the length of the transducer, then the temperature offset of active field sensor 18 is close to the average temperature offset of passive field sensor 19 and 20, in both cases, temperature offset of the transducer will be automatically eliminated using the above signal process algorithms.

Alternatively, passive field sensors 19 and 20 can also be placed close to magnetoelastic active zone 14, where their location has lower field strength than that of active field sensor 18, as shown in FIG. 5 a, there are several advantages of this arrangement, it require less axial space, it also partially compensate for temperature sensitivity drift, and partially compensate for rotational dependent output, since any temperature sensitivity drift and rotational dependent signal detected by active field sensor 18 will also experienced by passive field sensors 19 and 20. Although this arrangement will lower the transducer's sensitivity, with the above self-compensating feature, however, the transducer still capable of providing highly accurate measurement, immune from interfering external magnetic sources.

FIG. 5 b and FIG. 5 c show another kind of field sensor arrangement with passive field sensor 19 placed on only one side of the active field sensor 18. This kind of arrangement can be use in applications where the transducer is protected from near fields.

Although these field sensor arrangements is shown and explained in Polarized Band based magnetoelastic torque transducer, they may also be utilized in permeability based type of magnetoelastic torque transducer, by placing pickup coils without excite coils (passive field sensor) on either side of excite/pickup coils (active field sensor). Further more, other magnetic field sensing devices, such as magnetic speed sensor, magnetic linear position sensor, magnetic angle sensor, magnetic force sensor can also utilized these field sensor arrangements to filter out external magnetic flux and self-compensating for temperature offset.

In summary, embodiments of the invention have been described above in which following points are particularly noted.

-   -   a) A torque carry shaft with at least one magnetoelastic         transducer element zone can be used in a torque sensor by         sensing the change in the emanation of the magnetic flux form         the zone, because the amount of flux emanating from the shaft         varies with the torque applied.     -   b) At least one active magnetic field sensor and at least one         passive magnetic field sensor disposed in such a way that the         active field sensor always in a position with higher magnetic         field strength cause by interested objects, such as torque, than         that of the passive sensor. Passive field sensor can be placed         in both sides of the active field sensor, or on one side of         active field sensor only. The transducer output is obtained by         subtract the processed signal output of passive field sensor         from that of active field sensor, thus cancel out interfering         magnetic field flux and temperature offset on the transducer,         and partially filter out the transducer's temperature         sensitivity drift and rotational dependant signal.     -   c) The sensitivity of field sensors does not match to each other         perfectly in most cases due to manufacturing tolerance, they can         be electrically matched by calibrating field sensor's         sensitivity by putting the transducer inside a uniform magnetic         field. In doing so, common mode rejection will be completely         achieved.     -   d) There are several different kinds of magnetic flux field         sensors, such as Flux gate; Solid state sensor; Hall effect         sensor, Magnetoresistance device; Magnetometer; Compass;         Inductive coils, Magnetodiode, Magneto-Optical sensor, one or         more of these sensing elements may be used in conjunction with         the others.     -   e) The above torque sensor arrangements can be utilized in         Polarized Band based magnetoelastic torque sensor, as described         above, it can also be utilized in permeability based         magnetoelastic torque sensor by placing only passive pickup         coils next to excite and active pickup coils so that the         influence of interfering magnetic fields can be filter out.     -   f) Further more, other types of sensors that extract changes in         magnetic fields to indirectly detect direction, speed, presence,         force, linear position, or angle can also utilize above         arrangements to cancel out interfering magnetic fields.

While certain features and embodiments of the present invention have been described in detail herein, it is to be understood that the invention encompasses all modifications and enhancements within the scope and spirit of the following claim. 

1. A magnetic torque sensing system comprising: A member about a longitudinal axis, operably mounted to have a torque applied to the said member. Said member having a transducer element with at least one zone, which is either a respective integral portion of the shaft, or be directly or indirectly attached to or forming a part of the surface of said member. Said zone(s) being disposed along said longitudinal axis and being magnetized, its magnetic properties varies under applied torque and it is a function of a torque applied about said longitudinal axis. A magnetic sensor means arrangement comprising at least one active field sensor proximate to the peak field strength of said zone arise from applied torque, and at least one passive field sensor is placed farther away from said peak field strength than that of the active field sensor(s), thereby active field sensor(s) sensing more said magnetic flux than the passive field sensor, and Signal processing means to which said active field sensor(s) and said passive field sensor(s) are connected to cancel out the effects of external interfering magnetic flux or the effects of temperature offset, reduce the effects of rotational signal output and temperature sensitivity drift, and to develop an output signal representing the torque about said longitudinal axis.
 2. A torque sensor system of claim 1, wherein may be a Polarized Band based magnetoelastic torque sensor.
 3. A torque sensor system of claim 2, wherein at least one active sensor is disposed proximate to the said magnetoelastic zone.
 4. A torque sensor system of claim 3, wherein there is at least one passive sensor on both side of active field sensor or sensors disposed proximate the said magnetoelastic zone.
 5. A torque sensor system of claim 3, wherein there is at least one passive sensor on one side of active sensor disposed proximate to the said magnetoelastic zone.
 6. A torque sensor system of claim 1, wherein may be a permeability based magnetoelastic torque sensor.
 7. A torque sensor system of claim 6, wherein the excite/active pickup coils is disposed proximate to the said magnetoelastic zone.
 8. A torque sensor system of claim 6, wherein there is at least one passive pickup coil on both side of the excite/active pickup coils disposed proximate to the said magnetoelastic zone.
 9. A torque sensor system of claim 6, wherein there is at least one passive pickup coil on either side of the excite/active pickup coils disposed proximate to the said magnetoelastic zone.
 10. A magnetic field sensing arrangement for canceling external interfering magnetic fields and temperature offset effect comprising: positioning at least one active field sensor to transducer zone. positioning at least one passive field sensor outside of transducer zone or to the said zone with lower interested field strength than that of said active field sensor. measuring magnetic field with active and passive field sensors separately. determining magnetic field from active and passive field sensors respectively. determining external interfering magnetic field or temperature offset by processing magnetic field detected from passive field sensors, and subtracts the processed magnetic field of passive field sensors from that of active field sensor. converting the final magnetic field into output signal for the system.
 11. A magnetic field sensing arrangement claim 10, wherein there is at least one active sensor disposed proximate to the said transducer zone.
 12. A magnetic field sensing arrangement claim 10, wherein there is at least one passive sensor on one side of said active sensor.
 13. A magnetic field sensing arrangement claim 10, wherein there is at least one passive sensor on both side of said active sensor.
 14. A method for electrically match sensitivity of multiple magnetic field sensors in a transducer comprising: positioning two or more magnetic field sensors in line with each other. placing said field sensors inside a uniform magnetic field. determining magnetic field from each field sensor. matching output from each field sensor to make their outputs identical.
 15. A system as claimed in claim 14 wherein sensitivity of said field sensors may be matched in x direction.
 16. A system as claimed in claim 14 wherein sensitivity of said field sensors may be matched in y direction.
 17. A system as claimed in claim 1 wherein sensitivity of said field sensors may be matched in z direction. 